This manual covers the 125 Duke and RC 125 models, which share an engine platform with the 200 Duke and RC 200. These lightweight, performance-oriented motorcycles are known for their sporty character, aggressive styling, and rider engagement, embodying the "Ready To Race" philosophy. Designed for new riders, urban commuting, and enthusiastic street riding, they feature a liquid-cooled, single-cylinder, DOHC engine and a steel trellis frame, delivering an accessible yet exciting performance experience. Production for these models spanned from 1999 to 2006, with manufacturing primarily occurring in India. This comprehensive service and repair manual provides detailed information essential for the maintenance and repair of your motorcycle. It covers critical engine mechanicals, fuel and ignition systems, electrical components, and the exhaust system. Included are routine maintenance procedures, in-depth troubleshooting guides, disassembly and assembly instructions, rebuilding procedures, and a list of special tools. Detailed technical specifications, including torque values, clearances, and comprehensive wiring diagrams, are also provided to ensure accurate and efficient servicing. 🏷️ Basic Information Identification Make: KTM Model: 125 Duke / RC 125 (Engine Shared with 200 Duke / RC 200) Model Variant: Engine Service Repair Manual Platform: Shared engine platform for 125cc and 200cc models Codes Engine Code Common: LC4 (Designation may vary internally, but broadly refers to KTM's single-cylinder liquid-cooled engines of this era) 👋 Introduction Market Position Market Segment: Lightweight, performance-oriented entry-level sport motorcycles. Target Audience: New riders, commuting, urban riding, track day enthusiasts seeking accessible performance. Competitive Analysis Key Competitors: Yamaha R125/MT-125, Honda CBR125R/CB125F, Kawasaki Ninja 125/Z125. Key Features Engine Design: Liquid-cooled, single-cylinder, DOHC, 4-valve engine known for its free-revving nature and sporty character. Chassis Design: Trellis frame, high-quality suspension components (WP), aggressive styling derived from larger KTM sportbikes. Brand Philosophy: Ready To Race DNA, focusing on rider engagement and performance. 📋 Manual Details Coverage Areas Covered Models: KTM 125 Duke, KTM RC 125, KTM 200 Duke, KTM RC 200 Covered Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Page Count Estimated Page Count: 300-400 (Typical for comprehensive engine service manuals of this era) Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Cylinder head, valves, camshaft, pistons, connecting rods, crankshaft, lubrication system, cooling system, engine case, gaskets, seals. Fuel System: Carburetor (likely Keihin PD or similar), fuel tank, fuel lines, fuel filter, idle control. Ignition System: CDI unit, ignition coil, spark plug, stator, rotor, wiring diagrams. Exhaust System: Exhaust manifold, muffler, gaskets, mounting hardware. Electrical System: Wiring diagrams specific to engine components, charging system (stator, rectifier/regulator), starter motor, battery connections. Procedures Included Routine Maintenance: Oil changes, filter replacement, spark plug replacement, valve clearance adjustment, air filter cleaning/replacement, chain adjustment. Troubleshooting: Diagnostic procedures for common engine issues (no start, misfires, poor performance), diagnostic codes (if applicable). Disassembly Assembly: Step-by-step instructions for engine teardown, component inspection, and reassembly. Rebuilding: Detailed procedures for engine rebuilds, including piston ring replacement, bearing replacement, seal replacement, and cylinder honing. Special Tools: Identification and usage of specialized tools required for specific repair procedures. Technical Depth Diagnostic Procedures: In-depth diagnostic flowcharts and tests for electrical and mechanical systems. Component Specifications: Precise measurements for clearances, tolerances, torque specifications, and wear limits for all engine components. Wiring Diagrams: Comprehensive and detailed electrical wiring diagrams for engine management and related systems. Torque Values: Specific torque values for all fasteners and critical assembly points. Overhaul Procedures: Complete overhaul instructions for major engine sub-assemblies. 📊 Manual Specifications File Format File Format: PDF Searchability: Searchable text for quick information retrieval. Printability: Printable pages for workshop use. Print Quality Image Resolution: High-resolution images and diagrams for clarity. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled, DOHC, 4 valves Displacement 125: 124.7 cc Displacement 200: 199.5 cc Bore Stroke 125: 54 mm x 54.5 mm Bore Stroke 200: 65.5 mm x 58.5 mm Compression Ratio: Approx. 12.3:1 (Varies slightly between 125 and 200) Performance Horsepower 125: Approx. 15 hp (limited by A1 license regulations) Horsepower 200: Approx. 25 hp Torque 125: Approx. 12 Nm Torque 200: Approx. 19 Nm Fuel System Fuel Delivery: Carburetor (e.g., Keihin PJ or PD series) Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/95 RON Lubrication Lubrication System: Wet sump with oil pump Cooling System Cooling System: Liquid-cooled (radiator and fan) 🔧 Transmission Standard Transmission Type: 6-speed manual transmission Clutch Type: Wet multi-plate clutch Features Final Drive: Chain drive 📐 Dimensions Exterior Wheelbase: Approx. 1360 mm (varies slightly between Duke and RC) Weights Dry Weight: Approx. 115-130 kg (depending on model and specific configuration) Wet Weight: Approx. 129-142 kg (fully fueled, all fluids) 🛡️ Safety Features Ratings Safety Certification: CE certification for European markets. Active Features Braking System Front: Single disc brake with ByBre calipers (radial-mount on...